JOINT COMPOUND, WALL ASSEMBLY, AND METHODS AND PRODUCTS RELATED THERETO

• US 20150007519A1
• Filed: 09/22/2014
• Published: 01/08/2015
• Est. Priority Date: 09/25/2012
• Status: Active Grant

• Current Assignee: United States Gypsum Company (GEBR Knauf Verwaltungsgesellschaft KG)
• Original Assignee: United States Gypsum Company (GEBR Knauf Verwaltungsgesellschaft KG)
• Inventors: Negri, Robert H., Miklosz, Mark
• Granted Patent: US 9,140,015 B2
• Time in Patent Office: Days
• US Class Current: 52/417
• CPC Class Codes: C04B 14/24 porous, e.g. foamed glass
• CPC Class Codes: C04B 14/301 porous or hollow
• CPC Class Codes: C04B 16/08 porous, e.g. expanded polystyrene beads or microballoons
• CPC Class Codes: C04B 2103/0065 Polymers characterised by their glass transition temperature (Tg)
• CPC Class Codes: C04B 2103/0079 Rheology influencing agents
• CPC Class Codes: C04B 2103/406 non-ionic
• CPC Class Codes: C04B 2103/50 Defoamers, air detrainers
• CPC Class Codes: C04B 2103/67 Biocides
• CPC Class Codes: C04B 2111/00681 of the drying type
• CPC Class Codes: C04B 2111/10 Compositions or ingredients thereof characterised by the absence or the very low content of a specific material
• CPC Class Codes: C04B 26/06 Acrylates
• CPC Class Codes: C04B 26/14 Polyepoxides
• CPC Class Codes: C04B 26/16 Polyurethanes
• CPC Class Codes: C04B 26/18 Polyesters; Polycarbonates
• CPC Class Codes: C08K 7/28 Glass
• CPC Class Codes: C08L 2205/20 Hollow spheres
• CPC Class Codes: C08L 33/08 Homopolymers or copolymers of acrylic acid esters
• CPC Class Codes: E04F 13/02 of plastic materials hardening after applying, e.g. plaster surface treatment in painting technique B44D; inorganic or bituminous masses C04B; organic plastics C08L ; implements for applying plasticised materials E04F21/02
• CPC Class Codes: E04F 13/04 Bases for plaster sub-ceilings with plaster-carrying means E04B9/06
• CPC Class Codes: E04F 13/042 Joint tapes
• CPC Class Codes: E04F 13/06 : Edge-protecting borders borders for joints between plaster layers and window or door frames or like E06B1/62
• CPC Class Codes: E04F 13/0898 : with sealing elements between coverings sealings of joints between building constructions in general E04B1/68
• CPC Class Codes: E04F 2013/063 : for corners
• CPC Class Codes: E04F 2201/01 : Joining sheets, plates or panels with edges in abutting relationship

Abstract

A kit for assembling walls and ceilings is provided. The kit comprises at least two gypsum boards, each with at least one tapered edge, and a self-drying joint compound comprising a polymeric binder and hollow spheres. Methods for wall and ceiling installation are provided as well.

Claims

1. A kit for assembling at least one of the following:

a wall and a ceiling, the kit comprising;

(a) at least two gypsum boards, each of the boards having at least one tapered edge with a recess depth at the deepest point in the range from about 0.005 inch to about 0.125 inch; and

(b) a drying-type joint compound with shrinkage of less than 15% by volume as measured by ASTM C474-05, the drying-type joint compound comprising a plurality of hollow spheres and a binder selected from the group consisting of acrylic acid polymers, acrylic acid copolymers, alkyds, polyurethanes, polyesters, epoxies, and combinations thereof;

wherein the hollow spheres have an average isostatic crush strength of at least about 250 psi as measured according to ASTM D3102-78; and

wherein the density of the spheres is from about 0.0015 lb/in³ (about 0.04 g/cm³) to about 0.04 lb/in³ (about 1.1 g/cm³).

2. The kit of claim 1, wherein the binder in the joint compound is an acrylic acid polymer or acrylic acid copolymer.

3. The kit of claim 1, wherein the binder in the joint compound is in the form of an aqueous emulsion.

4. The kit of claim 1, wherein the joint compound has a density from about 2 lb/gal to about 8 lb/gal.

5. The kit of claim 1, wherein the joint compound exhibits shrinkage of about 2% or less by volume, as measured by ASTM C474-05.

6. The kit of claim 1, wherein the joint compound is substantially free of at least one of the following:

setting minerals, bulk filler, clays, starch, mica, calcium carbonate, expanded perlite, calcium magnesium carbonate, limestone, calcium sulfate dihydrate, attapulgite clay, kaolin clay, talcs and diatomaceous earth.

7. The kit of claim 1, wherein the binder in the joint compound has a glass transition temperature (Tg) from about 32°

F. to about 70°

F.

8. The kit of claim 1, wherein the hollow spheres are made from a material selected from the group consisting of lime boro-silicate, polystyrene, ceramic, recycled glass, expanded glass, lightweight polyolefin, and any combination thereof.

9. The kit of claim 1, wherein the joint compound further comprises a nonionic surfactant having a hydrophilic-lipophilic balance (HLB) from about 3 to about 20.

10. The kit of claim 1, wherein the kit further comprises at least one or more of the following:

a framing member, adhesive, reinforcement trim and joint tape.

11. A method for assembling at least one of the following:

a wall and a ceiling, the method comprising;

(a) obtaining a first gypsum board and a second gypsum board, each of the boards having at least one tapered edge with a recess depth at the deepest point in the range from about 0.005 inch to about 0.125 inch;

(c) obtaining a drying-type joint compound with shrinkage of less than 15% by volume as measured by ASTM C474-05, the drying-type joint compound comprising a plurality of hollow spheres and a binder selected from the group consisting of acrylic acid polymers, acrylic acid copolymers, alkyds, polyurethanes, polyesters, epoxies, and combinations thereof;

wherein the hollow spheres have an average isostatic crush strength of at least about 250 psi as measured according to ASTM D3102-78; and

wherein the density of the spheres is from about 0.0015 lb/in³ (about 0.04 g/cm³) to about 0.04 lb/in³ (about 1.1 g/cm³);

(d) joining the two gypsum boards together such that the tapered edges of the two boards create a seam; and

(e) applying the drying-type joint compound over the seam.

12. The method of claim 11, wherein the drying-type joint compound is applied in one coat only.

13. The method of claim 11, wherein the seam between the first gypsum board and the second gypsum board is further reinforced with a joint tape.

14. The method of claim 11, wherein at least one of the first gypsum board and the second gypsum board comprises a gypsum core sandwiched between two sheets of paper.

15. The method of claim 11, wherein each of the first gypsum board and the second gypsum board has a face surface and a back surface, and wherein the face surface of the first gypsum board and the face surface of the second gypsum board have at least one tapered edge, while the back surfaces are not tapered.

16. The method of claim 15, wherein the two gypsum boards are joined at the tapered edges to create a seam such that the two face surfaces stay on the same side and create a combined face surface, and the joint compound is applied over the seam on the combined face surface only.

17. The method of claim 11, wherein the method is performed in less than 48 hours.

18. The method of claim 11, wherein the method is performed in less than 24 hours.

19. The method of claim 11, wherein the method is performed in less than 72 hours.

20. The method of claim 11, wherein the step of applying the joint compound to the seam creates a substantially flat surface.